Highly-neutralized acid polymers and their use in golf balls

ABSTRACT

The present invention is directed to a golf ball having at least one layer, such as a center, a cover layer, or an intermediate layer, which is formed from a polymer composition comprising at least 25 wt %, based on the total polymeric weight of the polymer composition, of an acid polymer having acid groups, wherein at least 90% of the acid groups are neutralized. The polymer composition also comprises at least 10 wt %, based on the total polymeric weight of the polymer composition, of a non-fatty acid melt flow modifier selected from polyesters, polyacrylates, polyurethanes, polyethers, thermoplastic polyureas, and combinations thereof. The polymer composition is substantially free of fatty acids and their salts and has a melt flow index of from 0.5 g/10 min to 10.0 g/10 min.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of U.S. application Ser. No. 10/959,751, filed Oct. 6, 2004, now U.S. Pat. No. 7,230,045, which is a continuation-in-part of U.S. application Ser. No. 10/360,233, filed Feb. 6, 2003, now U.S. Pat. No. 6,939,907, which is a continuation-in-part of U.S. application Ser. No. 10/118,719, filed Apr. 9, 2002, now U.S. Pat. No. 6,756,436, which claims priority to U.S. Provisional Application No. 60/301,046, filed Jun. 26, 2001, now abandoned, the entire disclosures of which are hereby incorporated herein by reference.

FIELD OF THE INVENTION

The present invention is directed to polymer compositions including highly-neutralized acid polymers, and to the use of such compositions in golf balls.

BACKGROUND OF THE INVENTION

Conventional golf balls can be divided into two general classes: solid and wound. Solid golf balls include one-piece, two-piece (i.e., solid core and a cover), and multi-layer (i.e., solid core of one or more layers and/or a cover of one or more layers) golf balls. Wound golf balls typically include a solid, hollow, or fluid-filled center, surrounded by a tensioned elastomeric material, and a cover.

Golf ball core and cover layers are typically constructed with polymer compositions including, for example, polybutadiene rubber, polyurethanes, polyamides, ionomers, and blends thereof. Ionomers, particularly ethylene-based ionomers, are a preferred group of polymers for golf ball layers because of their toughness, durability, and wide range of hardness values.

Ionomers are stiffened by increasing the amount of neutralization. Neutralization to 70% and higher, including 100%, has been disclosed. However, in the absence of flow additives, at neutralization levels above about 60%, the melt flow of the ionomer is decreased to an extent such that processability decreases or disappears altogether. For trivalent cations, the percent neutralization at which the polymer becomes unprocessable, in the absence of flow additives, can be significantly lower.

Blending ionomers with fatty acids is a known method for improving the processability of highly neutralized polymers. For example, U.S. Pat. No. 6,653,382 discloses melt-processable, highly-neutralized ethylene acid copolymers and a process for making them by incorporating an aliphatic, mono-functional organic acid in the acid copolymer and then neutralizing greater than 90% of all of the acid groups present.

Another known method for improving the processability of highly neutralized polymers is blending ionomers with oxa acids. U.S. Patent Application Publication 2003/0225197 discloses a process for forming a golf ball having at least one layer, wherein the layer is formed of a polymer blend including a highly neutralized polymer formed from an oxa acid, a thermoplastic resin, and an inorganic metal compound, an organic amine, or a combination thereof, wherein greater than about 70% of the acid groups in the polymer blend are neutralized.

Blends of polyamides and highly neutralized ionomers are generally known. For example, U.S. Pat. No. 5,866,658 discloses blends of highly neutralized ionomers of copolymers of ethylene and high weight percentages of α,β-ethylenically unsaturated C₃-C₈ carboxylic acids dispersed in a continuous or co-continuous polyamide phase. Such blends are disclosed as being particularly useful in automotive applications, but their use in golf ball applications is not disclosed.

The use of polyamide-ionomer graft copolymers in golf ball compositions is known. U.S. Patent Application Publication No. 2002/0013413 and U.S. Pat. No. 6,579,938 disclose a golf ball with a cover or mantle, or both, formed from a composition comprising a polyamide-ionomer graft copolymer and a method of making the same. The ionomers are preferably neutralized from about 30% to about 65%. The references do not disclose neutralization of the ionomer above 90%.

A desire remains for novel compositions containing a highly neutralized acid polymer (“HNP”), which are useful in golf ball applications, and which are processable without the need for fatty acids or their salts. The present invention describes such compositions and their use in a variety of golf ball core and cover layers.

SUMMARY OF THE INVENTION

In one embodiment, the present invention is directed to a golf ball having a center which is formed from a polymer composition, the polymer composition comprising at least 25 wt %, based on the total polymeric weight of the polymer composition, of an acid polymer having acid groups, wherein at least 90% of the acid groups are neutralized. The polymer composition also comprises at least 10 wt %, based on the total polymeric weight of the polymer composition, of a non-fatty acid melt flow modifier selected from polyamides, polyesters, polyacrylates, polyurethanes, polyethers, thermoplastic polyureas, and combinations thereof. The polymer composition is substantially free of fatty acids and their salts and has a melt flow index of from 0.5 g/10 min to 10.0 g/10 min.

In another embodiment, the present invention is directed to a golf ball having a cover layer which is formed from a polymer composition, the polymer composition comprising at least 25 wt %, based on the total polymeric weight of the polymer composition, of an acid polymer having acid groups, wherein 100% of the acid groups are neutralized. The polymer composition also comprises at least 10 wt %, based on the total polymeric weight of the polymer composition, of a non-fatty acid melt flow modifier selected from polyesters, polyacrylates, polyurethanes, polyethers, thermoplastic polyureas, and combinations thereof. The polymer composition is substantially free of fatty acids and their salts and has a melt flow index of from 0.5 g/10 min to 10.0 g/10 min.

In yet another embodiment, the present invention is directed to a golf ball having at least one layer formed for a polymer composition, the polymer composition consisting essentially of from 25 wt % to 90 wt %, based on the total polymeric weight of the polymer composition, of an acid polymer, the acid groups of which are 100% neutralized; from 10 wt % to 75 wt %, based on the total polymeric weight of the composition, of a non-fatty acid melt flow modifier; and from 0 wt % to 60 wt %, based on the total weight of the polymer composition, of an inorganic additive. The non-fatty acid melt flow modifier has a melt flow index of from 10 g/10 min to 1,000 g/10 min, a weight average molecular weight of from 1,000 to 100,000, and is selected from polyesters, polyacrylates, polyurethanes, polyethers, thermoplastic polyureas, and combinations thereof. The polymer composition is substantially free of fatty acids and their salts and has a melt flow index of from 1.0 g/10 min to 5.0 g/10 min.

DETAILED DESCRIPTION OF THE INVENTION

Golf balls of the present invention include one-piece, two-piece, multi-layer, and wound golf balls having a variety of core structures, intermediate layers, covers, and coatings. Golf ball cores may consist of a single, unitary layer, comprising the entire core from the center of the core to its outer periphery, or they may consist of a center surrounded by at least one outer core layer. The center, innermost portion of the core is preferably solid, but may be hollow or liquid-, gel-, or gas-filled. The outer core layer may be solid, or it may be a wound layer formed of a tensioned elastomeric material. Golf ball covers may also contain one or more layers, such as a double cover having an inner and outer cover layer. Optionally, additional layers may be disposed between the core and cover. In the golf balls of the present invention, at least one layer comprises an HNP-containing composition described herein. Preferably, the HNP-containing composition is included as an intermediate layer, preferably an outer core layer or inner cover layer, of a multi-layer golf ball.

The HNP-containing compositions of the present invention include one or more highly neutralized acid polymer(s) and one or more non-fatty acid melt flow modifier(s). By the present invention, it has been found that by adding a sufficient amount of a non-fatty acid melt flow modifier to compositions containing an acid polymer, the acid groups of the acid polymer can be neutralized at high levels, including up to 100%, without requiring a fatty acid to maintain process ability.

The HNP-containing compositions may contain fatty acids and salts thereof, but are processable without them. Fatty acids include, for example, caproic acid, caprylic acid, capric acid, lauric acid, stearic acid, behenic acid, erucic acid, oleic acid, and linoleic acid. Preferably, the HNP-containing composition is substantially free of fatty acids and their salts. “Substantially free,” as used herein, means that the composition does not contain fatty acids or their salts, or includes fatty acids or their salts in an amount of less than 0.5 wt %, based on the total polymeric weight of the composition.

In order to be processable, the HNP-containing composition has a melt flow index of at least 0.5 g/10 min. Preferably, the melt flow index of the HNP-containing composition is from 0.5 g/10 min to 10.0 g/10 min, more preferably from 1.0 g/10 min to 5.0 g/10 min, and even more preferably from 1.0 g/10 min to 4.0 g/10 min.

The non-fatty acid melt flow modifiers of the present invention are generally thermoplastics having a melt flow index of from 10 g/10 min to 1,000 g/10min and a weight average molecular weight (M_(W)) of at least 100. Preferably the M_(W) of the non-fatty acid melt flow modifier is at least 500, more preferably at least 1,000. Alternatively, the M_(W) of the non-fatty acid melt flow modifier is from 500 to 150,000, preferably from 1,000 to 100,000. Preferably, the non-fatty acid melt flow modifier is selected from polyamides, polyesters, polyacrylates, polyurethanes, polyethers, thermoplastic polyureas, and combinations thereof.

Other suitable non-fatty acid melt flow modifiers include oligomeric- and polymeric-plasticizers such as fatty alcohols, fatty acid amides, fatty acid esters, paraffin and other waxes, oxidized and non-oxidized polyethylene waxes, silicone homopolymers and copolymers, fluoropolymers, epoxies, phosphorus-based materials, silanes, ammonium compounds, amides, amines (e.g., ethoxylated cocoalkyl amine), coupling agents (e.g., titanates, zirconates), ionic liquids, triglycerides, lipids (e.g., sphingolipids), polyester polyols, thioesters, thioethers, adipates, phthalates, polyadipates, polyphthalates, and combinations thereof.

The amount of non-fatty acid melt flow modifier present in the HNP-containing compositions of the present invention is typically at least 5 wt %, preferably at least 10 wt %, more preferably from 5 wt % to 75 wt %, even more preferably from 10 wt % to 70 wt %, and even more preferably from 15 wt % to 55 wt %, based on the total polymeric weight of the composition. The amount of acid polymer present in the HNP-containing compositions of the present invention is typically at least 25 wt %, preferably from 25 wt % to 95 wt %, more preferably from 30 wt % to 90 wt %, and even more preferably from 45 wt % to 85 wt %, based on the total polymeric weight of the composition.

The acid polymers of the present invention are generally homopolymers and copolymers of α,β-ethylenically unsaturated mono- or dicarboxylic acids, including combinations thereof. The term “copolymer,” as used herein, includes polymers having two types of monomers, those having three types of monomers, and those having more than three types of monomers. Preferred α,β-ethylenically unsaturated mono- or dicarboxylic acids are (meth) acrylic acid, ethacrylic acid, maleic acid, crotonic acid, fumaric acid, itaconic acid. (Meth) acrylic acid is most preferred. As used herein, “(meth) acrylic acid” means methacrylic acid and/or acrylic acid. Likewise, “(meth) acrylate” means methacrylate and/or acrylate.

Preferred acid polymers are copolymers of a C₃ to C₈ α,β-ethylenically unsaturated mono- or dicarboxylic acid and ethylene or a C₃ to C₆ α-olefin, optionally including a softening monomer. Particularly preferred acid polymers are copolymers of ethylene and (meth) acrylic acid, preferably including a softening monomer. When a softening monomer is included, such copolymer is referred to herein as an E/X/Y-type copolymer, wherein E is ethylene, X is a C₃ to C₈ α,β-ethylenically unsaturated mono- or dicarboxylic acid, and Y is a softening monomer. The softening monomer is typically an alkyl (meth) acrylate, wherein the alkyl groups have from 1 to 8 carbon atoms. Preferred E/X/Y-type copolymers are those wherein X is (meth) acrylic acid and/or Y is selected from (meth) acrylate, n-butyl (meth) acrylate, isobutyl (meth) acrylate, methyl (meth) acrylate, and ethyl (meth) acrylate. More preferred E/X/Y-type copolymers are ethylene/(meth) acrylic acid/n-butyl acrylate, ethylene/(meth) acrylic acid/methyl acrylate, and ethylene/(meth) acrylic acid/ethyl acrylate.

The amount of ethylene or C₃ to C₆ α-olefin in the acid copolymer is typically at least 15 wt %, preferably at least 25 wt %, more preferably least 40 wt %, even more preferably at least 60 wt %, and even more preferably from 80 wt % to 85 wt %, based on the total weight of the copolymer. The amount of C₃ to C₈ α,β-ethylenically unsaturated mono- or dicarboxylic acid in the acid copolymer is typically from 1 wt % to 35 wt %, preferably from 5 wt % to 30 wt %, more preferably from 5 wt % to 25 wt %, even more preferably from 10 wt % to 20 wt %, and even more preferably 15 wt % to 20 wt %, based on the total weight of the copolymer. The amount of optional softening comonomer in the acid copolymer is typically from 0 wt % to 50 wt %, preferably from 5 wt % to 40 wt %, more preferably from 10 wt % to 35 wt %, and even more preferably from 20 wt % to 30 wt %, based on the total weight of the copolymer.

Further examples of suitable acid polymers include Surlyn® ionomers, commercially available from DuPont; AClyn® ionomers, commercially available from Honeywell International Inc.; Iotek® ionomers, commercially available from ExxonMobil Chemical Company; and the acid copolymers described in U.S. Patent Application Publication No. 2003/0130434, the entire disclosure of which is hereby incorporated herein by reference.

The acid polymers of the present invention can be direct copolymers wherein the polymer is polymerized by adding all monomers simultaneously, as described in, for example, U.S. Pat. No. 4,351,931, the entire disclosure of which is hereby incorporated herein by reference. Ionomers can be made from direct copolymers, as described in, for example, U.S. Pat. No. 3,264,272 to Rees, the entire disclosure of which is hereby incorporated herein by reference. Alternatively, the acid polymers of the present invention can be graft copolymers wherein a monomer is grafted onto an existing polymer, as described in, for example, U.S. Patent Application Publication No. 2002/0013413, the entire disclosure of which is hereby incorporated herein by reference.

As used herein, “highly neutralized acid polymer” refers to the acid polymer after at least 90%, preferably at least 95%, more preferably at least 98%, and even more preferably 100%, of the acid groups thereof are neutralized by a cation source. Neutralization can be effected prior to, during, or after combining the acid polymer(s) with the melt flow modifier(s).

Suitable cation sources include metal cations and salts thereof, organic amine compounds, ammonium, and combinations thereof. Preferred cation sources are metal cations and salts thereof, wherein the metal is preferably lithium, sodium, potassium, magnesium, calcium, barium, lead, tin, zinc, aluminum, manganese, nickel, chromium, copper, or a combination thereof. Particularly preferred metals are zinc, magnesium, lithium, and sodium. The amount of cation used in the HNP-containing composition is readily determined based on the desired level of neutralization.

HNP-containing compositions of the present invention typically have a flexural modulus of from 3,000 psi to 200,000 psi, preferably from 5,000 psi to 150,000 psi, more preferably from 10,000 psi to 125,000 psi, and even more preferably from 20,000 psi to 100,000 psi. The material hardness of the HNP-containing compositions is generally from 30 Shore D to 80 Shore D, preferably from 40 Shore D to 75 Shore D, and more preferably from 45 Shore D to 70 Shore D. The notched izod impact strength of the HNP-containing compositions of the present invention is generally at least 2 ft.lb/in, as measured at 23° C. according to ASTM D256. The dart impact is generally at least 180 ft.lb/in².

HNP-containing compositions of the present invention may contain one or more additives in an amount of from 0 wt % to 60 wt %, based on the total weight of the composition. Suitable additives include, but are not limited to, chemical blowing and foaming agents, optical brighteners, coloring agents, fluorescent agents, whitening agents, UV absorbers, light stabilizers, defoaming agents, processing aids, mica, talc, nano-fillers, antioxidants, stabilizers, softening agents, fragrance components, plasticizers, impact modifiers, TiO₂, acid copolymer wax, surfactants, and fillers, such as zinc oxide, tin oxide, barium sulfate, zinc sulfate, calcium oxide, calcium carbonate, zinc carbonate, barium carbonate, clay, tungsten, tungsten carbide, silica, lead silicate, regrind (recycled material), moisture scavengers, moisture barrier materials and layers thereof, and mixtures thereof. Suitable additives are more fully described in, for example, U.S. Patent Application Publication No. 2003/0225197, the entire disclosure of which is hereby incorporated herein by reference.

The HNP-containing compositions can optionally be blended with additional thermoplastic and thermoset materials, including, but not limited to, ionomers, acid copolymers, engineering thermoplastics, fatty acid/salt-based highly neutralized polymers, polybutadienes, polyurethanes, polyesters, thermoplastic elastomers, and other conventional polymeric materials.

The present invention is not limited by any particular method for making the HNP-containing composition. In one embodiment, the composition is prepared by an extrusion process utilizing a melt extruder, such as a single or twin screw extruder. In a typical extruder process, the acid polymer(s), melt flow modifier(s), and optional additives are fed, either simultaneously or separately, into the extruder and melt blended at a temperature typically within the range of from 200° C. to 550° C. The cation source is concurrently or subsequently added to neutralize the acid polymer(s) to a desired level. The acid polymer(s) may be partially neutralized prior to contact with the cation source. In another embodiment, the composition is prepared by heating and reacting the acid polymer(s) and melt flow modifier(s) in solution at a temperature above the melting point of the polymeric components.

HNP-containing compositions of the present invention can be used in a variety of applications. For example, HNP-containing compositions are suitable for use in golf equipment, including, but not limited to, golf balls, golf shoes, and golf clubs.

Golf balls of the present invention can be wound, one-piece, two-piece, or multi-layer balls, wherein at least one layer comprises an HNP-containing composition described herein. In golf balls having two or more layers which comprise an HNP-containing composition, the HNP-containing composition of one layer may be the same or a different HNP-containing composition as another layer. The layer(s) comprising the HNP-containing composition can be any one or more of a core layer, an intermediate layer, or a cover layer. In a preferred embodiment, the golf ball is a two-piece or multi-layer ball having a center formed from an HNP-containing composition described herein. Preferably, the center has a diameter of from 0.50 in to 1.63 in, more preferably from 1.00 in to 1.63 in, and an Atti compression of from 40 to 160. Preferably, the center has a surface hardness of from 20 Shore D to 70 Shore D. In another preferred embodiment, the golf ball is a multi-layer ball having an intermediate layer, such as an inner cover layer or outer core layer, disposed between a core and an outer cover layer, wherein the intermediate layer is formed from an HNP-containing composition described herein. Preferably, the intermediate layer has a material hardness of from 30 Shore D to 80 Shore D. Preferably, the intermediate layer has a thickness of from 0.020 in to 0.090 in, more preferably from 0.010 in to 0.060 in. In yet another preferred embodiment, the golf ball is a two-piece or multi-layer ball having an outer cover layer formed from an HNP-containing composition described herein.

The present invention is not limited by any particular process for forming the golf ball layer(s). It should be understood that the layer(s) can be formed by any suitable technique, including injection molding, compression molding, casting, and reaction injection molding.

Preferred golf balls of the present invention are multi-layer balls having a compression molded rubber core, at least one injection or compression molded intermediate layer which comprises an HNP-containing composition, and a cast or reaction injection molded polyurethane or polyurea outer cover layer. Light stable polyureas and polyurethanes are preferred for the outer cover layer material. Preferably, the rubber core composition comprises a base rubber, a crosslinking agent, a filler, a co-crosslinking or initiator agent, and a cis to trans converting material (e.g., organosulfur and inorganic sulfur compounds). Typical base rubber materials include natural and synthetic rubbers, including, but not limited to, polybutadiene and styrene-butadiene. The crosslinking agent typically includes a metal salt, such as a zinc salt or magnesium salt, of an acid having from 3 to 8 carbon atoms, such as (meth) acrylic acid. The initiator agent can be any known polymerization initiator which decomposes during the cure cycle, including, but not limited to, dicumyl peroxide, 1,1-di-(t-butylperoxy) 3,3,5-trimethyl cyclohexane, a-a bis-(t-butylperoxy) diisopropylbenzene, 2,5-dimethyl-2,5 di-(t-butylperoxy) hexane or di-t-butyl peroxide, and mixtures thereof. Suitable types and amounts of base rubber, crosslinking agent, filler, co-crosslinking agent, and initiator agent are more fully described in, for example, U.S. Patent Application Publication No. 2003/0144087, the entire disclosure of which is hereby incorporated herein by reference. Reference is also made to U.S. Patent Application Publication No. 2003/0144087 for various ball constructions and materials that can be used in golf ball core, intermediate, and cover layers.

Golf balls of the present invention generally have a coefficient of restitution (“COR”) of at least 0.790, preferably at least 0.800, more preferably at least 0.805, and even more preferably at least 0.810, and an Atti compression of from 75 to 110, preferably from 90 to 100. As used herein, COR is defined as the ratio of the rebound velocity to the inbound velocity when balls are fired into a rigid plate. In determining COR, the inbound velocity is understood to be 125 ft/s.

EXAMPLES

It should be understood that the examples below are for illustrative purposes only. In no manner is the present invention limited to the specific disclosures therein.

Seventeen compositions according to the present invention were prepared by blending one or more partially neutralized acid polymers (Surlyn® ionomers), a melt flow modifier (Rilsan® polyamide), and zinc oxide or magnesium oxide as a cation source. In the resulting compositions, the acid groups of the acid polymers were 100% neutralized. Each composition was used as the inner cover layer of a golf ball, and various properties of the golf ball at different stages of ball construction were evaluated.

The materials used in the examples below include Rilsan® BMNO and AMNO polyamide resins, commercially available from Arkema Inc., and Surlyn® ionomers, commercially available from DuPont. Surlyn® 8320 is a very low modulus ethylene/methacrylic acid/butyl acrylate (E/MAA/butyl acrylate) copolymer, in which the MAA acid groups have been partially neutralized with sodium ions. Surlyn® 9320 is a very low modulus E/MAA/butyl acrylate copolymer, in which the MAA acid groups have been partially neutralized with zinc ions. Surlyn® 8940 is an E/MAA copolymer, in which the MAA acid groups have been partially neutralized with sodium ions. Surlyn® 7940 is an E/MAA copolymer, in which the MAA acid groups have been partially neutralized with lithium ions. Surlyn® 6910 is a magnesium ionomer. Surlyn® 6320 is a medium acid, very low modulus magnesium ionomer.

As used herein, “melt flow index” refers to the melt flow index as measured using a 2.16 kg weight at 210° C., unless stated otherwise, and was measured in the examples below according to ASTM D1238. Flexural modulus was measured using flex bars, which were prepared and measured according to ASTM D790. Hardness was measured according to ASTM D2240. In the tables below, wt % is based on the total polymeric weight of the composition, and “pph” is defined as parts per hundred parts of polymer.

Comparative Example

The comparative example is a 50/50 wt % blend of Surlyn® 7940 and Surlyn® 8940, wherein the neutralization level of the blend is less than 60%.

Examples 1-6

In Examples 1-6, HNP-containing compositions were prepared by melt blending an acid polymer selected from Surlyn® 8320 and Surlyn® 9320, Rilsan® BMNO (polyamide 11) as a melt flow modifier, and zinc oxide as a cation source, in a twin screw extruder, at a temperature of at least 450° F. (230° C.). The relative amounts of each component used are indicated in Table 1. The melt flow index, measured at 190° C., and specific gravity of each HNP-containing composition were measured, and the results are reported in Table 1.

TABLE 1 Melt Flow Rilsan ® Surlyn ® Surlyn ® Surlyn ® Surlyn ® zinc oxide, Index, Specific % Acid Groups Example BMNO, lb 8320, lb 9320, lb 7940, wt % 8940, wt % lb g/10 min Gravity Neutralized 1 9.14 3.42 0 0 0 2.28 5.45 1.153 100 2 14.20 9.77 0 0 0 3.55 3.54 1.110 100 3 10.70 5.33 0 0 0 2.66 4.18 1.129 100 4 9.14 0 3.42 0 0 2.28 4.81 1.134 100 5 14.20 0 9.77 0 0 3.55 6.71 1.127 100 6 10.70 0 5.33 0 0 2.66 3.00 1.138 100 Comparative 0 0 0 50 50 0 2.3 0.96 <60

Flex bars of each HNP-containing composition were formed and evaluated for flexural modulus and hardness. The results are reported in Table 2.

TABLE 2 Flexural Flexural Modulus Modulus Shore D Shore D Shore C Shore C at 40 at 2 Hard- Hard- Hard- Hard- hours, weeks, ness at ness at ness at ness at Example psi psi 1 week 2 weeks 1 week 2 weeks 1 106,300 108,900 67 66 93 93 2 78,600 79,900 64 63 91 92 3 88,300 93,100 65 65 92 91 4 99,500 100,600 65 65 92 93 5 92,600 99,000 65 64 91 92 6 100,400 105,000 65 65 92 92

Each of the above compositions was injection molded over a rubber core to form casings, i.e., an intermediate product in golf ball construction which comprises a core covered with a layer which will be an intermediate layer in the finished ball. The core was a crosslinked pokybutadiene-based composition compression molded into a sphere having a diameter of 1.55 in (3.94 cm), an Atti compression of 75, and a COR of 0.803. The casings were evaluated for diameter, Atti compression, hardness, and COR. The results are reported in Table 3.

TABLE 3 Diameter, Atti Shore D Shore C Example in Compression Hardness Hardness COR 1 1.618 86 66 94 0.819 2 1.619 84 61 93 0.818 3 1.619 86 64 93 0.818 4 1.620 88 64 94 0.815 5 1.619 87 65 93 0.815 6 1.619 87 64 93 0.816 Comparative 1.620 82 60 91 0.815

An outer cover layer of aliphatic polyurethane having a Shore D hardness of 45 was cast over each casing to form finished balls. The finished balls were evaluated for diameter, compression, hardness, COR, and initial velocity. The results are reported in Table 4.

TABLE 4 Dia- Atti Shore D Shore C Initial meter, Compres- Hard- Hard- Velocity, Example in sion ness ness COR ft/s 1 1.689 95 57 80 0.799 252.4 2 1.689 91 57 80 0.795 252.1 3 1.688 91 57 80 0.799 252.4 4 1.689 94 57 80 0.793 251.9 5 1.688 93 58 81 0.793 251.9 6 1.689 93 59 80 0.796 251.7 Comparative 1.688 90 58 80 0.801 252.8

Examples 7-11

In Examples 7-11, HNP-containing compositions were prepared by the same method used in Examples 1-6, except that the acid polymer was Surlyn® 8940. The relative amounts of each component used are indicated in Table 5. The melt flow index, measured at 190° C., and the specific gravity of each HNP-containing composition were measured, and the results are reported in Table 5.

TABLE 5 Melt Flow Rilsan ® Surlyn ® Surlyn ® zinc oxide, Index, Specific % Acid Groups Example BMNO, wt % 7940, wt % 8940, wt % pph g/10 min Gravity Neutralized 7 55.0 0 45.0 2.5 19.4 1.009 100 8 40.0 0 60.0 2.5 14.1 1.000 100 9 30.0 0 70.0 2.5 7.7 0.984 100 10  20.0 0 80.0 2.5 7.3 0.972 100 11  10.0 0 90.0 2.5 8.3 0.976 100 Comparative 0 50 50 0 2.3 0.96 <60

Flex bars of each of the above compositions were formed and evaluated for flexural modulus and hardness. The results are reported in Table 6.

TABLE 6 Flexural Flexural Shore D Shore D Shore C Shore C Modulus Modulus Hard- Hard- Hard- Hard- at 40 at 2 ness ness ness ness hours, weeks, at 40 at 2 at 40 at 2 Example psi psi hours weeks hours weeks 7 124,200 129,200 67 67 93 93 8 109,600 116,400 65 66 92 92 9 98,800 110,800 63 65 90 90 10  81,100 96,500 62 65 89 90 11  69,500 86,000 60 65 89 90 Compar- * 62,400 60 61 84 87 ative * not measured

Each of compositions 7-10 was injection molded over a rubber core to form casings. The core was a crosslinked polybutadiene-based composition compression molded into a sphere having a diameter of 1.55 in, an Atti compression of 71, and a COR of 0.804. The casings were evaluated for diameter, Atti compression, hardness, and COR. The results are reported in Table 7.

TABLE 7 Diameter, Atti Shore D Shore C Example in Compression Hardness Hardness COR 7 1.616 85 68 96 0.825 8 1.618 83 66 95 0.820 9 1.617 82 64 93 0.820 10  1.609 80 63 92 0.817 Comparative 1.620 81 60 91 0.815

An outer cover layer of aromatic polyurethane having a Shore D hardness of 45 was cast over each casing to form finished balls. The finished balls were evaluated for diameter, compression, hardness, COR, and initial velocity. The results are reported in Table 8.

TABLE 8 Dia- Atti Shore D Shore C Initial meter, Compres- Hard- Hard- Velocity, Example in sion ness ness COR ft/s 7 1.687 91 59 79 0.810 253.9 8 1.688 90 59 78 0.807 253.6 9 1.685 89 57 79 0.808 253.7 10  1.687 87 55 80 0.807 253.5 Comparative 1.686 87 56 78 0.804 253.5

Examples 12-17

In Examples 12-17, HNP-containing compositions were prepared by the same method used in Examples 1-6, except that the acid polymer was selected from Surlyn® 6910, Surlyn® 6320, and a combination thereof, the melt flow modifier was Rilsan® AMNO (polyamide 12), and the cation source was magnesium oxide. The relative amounts of each component used are indicated in Table 9. The melt flow index, measured at 190° C., of each HNP-containing composition was measured, and the results are reported in Table 9.

TABLE 9 Rilsan ® Surlyn ® Surlyn ® Surlyn ® Surlyn ® Magnesium % Acid Groups Example AMNO, lb 6910, lb 6320, lb 7940, wt % 8940, wt % oxide, lb Neutralized 12 1.0 1.0 0 0 0 0.08 100 13 1.0 3.0 0 0 0 0.08 100 14 1.0 1.5 1.5 0 0 0.08 100 15 2.0 2.0 0 0 0 0.05 100 16 1.0 0 7.0 0 0 0.05 100 17 0 0 7.0 0 0 0.05 100 Comparative 0 0 0 50 50 0 <60

Flex bars of each HNP-containing composition were formed and evaluated for flexural modulus and hardness. The results are reported in Table 10.

TABLE 10 Flexural Modulus Flexural Modulus Flexural Modulus Shore D Hardness Shore D Hardness Shore C Hardness Shore C Hardness Example at 40 hours, psi at 3 days, psi at 2 weeks, psi at 40 hrs at 2 weeks at 40 hrs at 2 weeks 12 76,300 73,400 79,400 62 61 88 87 13 44,300 45,400 51,300 54 55 81 82 14 38,200 40,800 47,700 57 59 85 87 15 58,900 62,300 73,800 62 63 89 90 16 44,200 48,900 59,600 59 60 87 89 17 42,500 46,700 56,300 59 59 87 88

Each of compositions 12 and 13 was injection molded over a rubber core to form casings. The core was a crosslinked polybutadiene-based composition compression molded into a sphere having a diameter of 1.55 in (3.94 cm), an Atti compression of 73, and a COR of 0.796. The casings were evaluated for diameter, Atti compression, and COR. The results are reported in Table 11.

TABLE 11 Example Diameter, in Atti Compression COR 12 1.619 81 0.810 13 1.619 75 0.802

Other than in the operating examples, or unless otherwise expressly specified, all of the numerical ranges, amounts, values and percentages such as those for amounts of materials, and others in the specification may be read as if prefaced by the word “about” even though the term “about” may not expressly appear with the value, amount or range. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in its respective testing measurements. Furthermore, when numerical lower limits and numerical upper limits are set forth herein, it is contemplated that any combination of these values may be used.

All patents, publications, test procedures, and other references cited herein, including priority documents, are fully incorporated by reference to the extent such disclosure is not inconsistent with this invention and for all jurisdictions in which such incorporation is permitted.

While the illustrative embodiments of the invention have been described with particularity, it will be understood that various other modifications will be apparent to and can be readily made by those of ordinary skill in the art without departing from the spirit and scope of the invention. Accordingly, it is not intended that the scope of the claims appended hereto be limited to the examples and descriptions set forth herein, but rather that the claims be construed as encompassing all of the features of patentable novelty which reside in the present invention, including all features which would be treated as equivalents thereof by those of ordinary skill in the art to which the invention pertains. 

1. A golf ball having a cover layer, wherein the cover layer is formed from a polymer composition comprising: at least 25 wt %, based on the total polymeric weight of the polymer composition, of an acid polymer having acid groups, wherein 100% of the acid groups are neutralized; and at least 10 wt %, based on the total polymeric weight of the polymer composition, of a non-fatty acid melt flow modifier selected from the group consisting of polyesters, polyacrylates, polyurethanes, polyethers, thermoplastic polyureas, and combinations thereof; wherein the polymer composition is substantially free of fatty acids and their salts and has a melt flow index of from 0.5 g/10 min to 10.0 g/10 min.
 2. The golf ball of claim 1, wherein the non-fatty acid melt flow modifier has a melt flow index of from 10 g/10 min to 1,000 g/10 min and a weight average molecular weight of from 1,000 to 100,000.
 3. The golf ball of claim 1, wherein the cover layer is an inner cover layer having a thickness of from 0.010 in to 0.060 in.
 4. The golf ball of claim 1, wherein the cover layer has a material hardness of from 30 Shore D to 80 Shore D.
 5. The golf ball of claim 1, wherein the polymer composition consists essentially of: from 25 wt % to 90 wt %, based on the total polymeric weight of the polymer composition, of the acid polymer; from 10 wt % to 75 wt %, based on the total polymeric weight of the polymer composition, of the non-fatty acid melt flow modifier; and from 0 wt % to 60 wt %, based on the total weight of the polymer composition, of an inorganic additive.
 6. The golf ball of claim 1, wherein the polymer composition has a flexural modulus of from 10,000 psi to 125,000 psi.
 7. The golf ball of claim 1, wherein the polymer composition has a notched izod impact strength of at least 2 ft·lb/in. 